Method of transporting and storing prepared foods



Oc. 16, 1956 H. W. CLARKE v METHOD OF' TRAANSPORTING AND STORING PREPARED FOODS 3 Sheets-Sheet 1 Filed July 2, 1953 ,36 a Bnnentor fang/,12,7 buf/M@ Gttornegs Oct. 16, 1956 H. w. CLARKE METHOD OF' TRANSPORTING AND STORING PREPARED FOODS 3 Shets-Sheet 3 Filed July 2, 1953 E amw, Zas-fw Gttornegs Oct. 16, 1956 H. w. CLARKE METHOD OF' TRANSPORTING AND STORING PREPARED FOODS 3 Sheets-Sheet 2 Filed July 2, 1953 Gttornegs' United States Patent METHOD F TRANSPORTING AND STRING PREPARED FOODS Houghton W. Clarke, Evanston, lill., assignor of ninetynine percent to Mealpack Corporation, Evanston, Ill., a corporation of Illinois Application July 2, 1953, Serial No. 365L614 Claims. (Cl. 99-171)' This invention relates to a method of transporting and storing prepared food. More particularly, the invention relates to a method and means for serving prepared meals where such food is transported for some distance and then served to patients, workers, and other consumers.

This application is a continuation-in-part of my copending applications which have matured into Patents No. 2,436,097, No. 2,656,946, and No. 2,699,813, and of my copending application, Serial No. 297,727, liled July 8, 1952, now abandoned.

It is frequently necessary, in serving meals, to prepare the foods and serve them in the dishes a considerable time before they are consumed. When it is desired to provide meals for workers, particularly in mines and large plants, it has frequently been considered impracticable to serve complete meals, including hot or chilled foods, because of the distances which it is necessary to transport the meals before serving them to the workers.

An object of the present invention is to provide a method and means for serving foods and beverages so as to keep the food or beverages in perfect condition and without serious objectionable change of temperature or deterioration in quality while in transport or awaiting transport to the consumer. A further object is to provide a method whereby food is kept hot and in excellent condition even during the period in which the food is being eaten. Other objects and advantages of the invention will be apparent from the following description and the accompanying drawings, in which- Figure 1 is a perspective view from the front of a structure embodying my invention; Fig. 2, a perspective view of the container of Fig. l opened, but with the foods still sealed therein; Fig. 3, a plan view of the dish of Fig. 2; Fig. 4, a View in vertical axial section through the container of Fig. l, but with different receptacles; Fig. 5, a plan view similar to Fig. 3 but showing the receptacles of Fig. 4; and Fig. 6, an isometric View of a packing table and conveyor used in my invention.

Referring now to Figures 1-4, the insulating container there shown is composed of two halves. The lower part a is made of two shells 11a and 13a of drawn (e. g., by stamping or spinning) sheet metal, advantageously bright stainless steel sheet. These shells are sealed and locked together by the rubber gasket ring 40a.

rl'he upper part 15a is made in the same way as the two shells 16a and 18a, being also of drawn (e. g., by stamping or spinning) sheet metal, advantageously bright stainless steel. The two shells are sealed and locked together by a gasket 40a identical with that described for sealing and holding together the shells 11a and 13a. The space between the shells in both parts is advantageously filled with a thermal insulating material 19a, e. g., sponge glass, glass wool, wood fiber in loosely formed felt, etc. This insulation is preformed to lit the space between the shells so that there will be no excessive packing and to the same end an abutment ring 70a is placed in the bottom to limit the relative movement between the shells 11a- 13a or 16a-18a.

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In assembling, the gaskets, which are made of extruded tubing of the cross-sectional shape shown, are cut to proper length with skived ends and these ends cemented and/ or vulcanized together to give a ring of the diameter required for the gaskets 40a. The gasket is applied to the outer ring with the lip 12a in the peripheral slot of the gasket. The gasket ring is then rolled outward so as to bring the ange 71a beyond the lip 12a. The inner shell 13a is now inserted through the gasket until its lip 72a engages the gasket. The latter is then stretched over the lip 72a, bringing the flange 71a against lip 72a. The shell 13a is then pushed down to the position shown in Fig. 4. As lip 72a passes lip 12a, the gasket 40a is compressed tightly together and as it passes beyond the gasket, expands again. Thus, its resilient expansive force serves to hold the parts securely together. Advantageously, this assembly is performed in partial vacuum or the space between the shells is evacuated by means of a hypodermic needle inserted through the gasket.

The upper part 15a, in the embodiment shown in Figs. 1-4, is similar in form and construction to the lower except that instead of the annular projection 27a on the bottom, an annular recess 26a is formed in the top adapted to intert with 27a for stacking of containers for use of the cover as a table or lap tray. The use of a deep cover as shown in these figures is an advantage in that it raises the dish to a level above the lap more convenient for eating. The projection 27a is made with just a little smaller diameter than that of the gaskets 40a so that the cover and body are held aligned whether the cover is used right side up or inverted. The projection 27a, whether annular as shown, or of different form, is rounded on the bottom so that it will make only tangential contact with any ordinary supporting surface on which it may be placed. Thus, heat loss by conduction is minimized.

A handle bail 21a may be provided on the top, if desired.

It will be observed that in this embodiment all surfaces are smooth, easily washed and sterilized, and as described are thermally reective and of low thermal conductivity stainless steel sheet. The rubber gaskets seal the space between the shells so that its thermal insulating quality is not impaired by moisture and there is no danger of unsanitary accumulations of food residues or soap being carried therein during washing. The container is rugged and foolproof and withstands much abuse, as Well as all normal use under widely varied conditions.

In Figs. 2 and 3, I have shown a dish 47a divided by partitions 57a -into receptacles 58a, 59a and 60a. The dish 47a is made of a material of low coeicient of thermal expansion, such that with the particular dish, the smooth contact line on which it is engaged and sealed by the removable lid 53a is not substantially distorted so as to impair the seal by normal use and handling of the dish. l have found the best material for this purpose is oven glass, such as the borosilicate glass generally known as Pyrex, which has a low coeliicient of thermal expansion (about 36X 10-7) and can be rapidly heated to and cooled from about 200 F. in one part (e. g., by putting hot food in only one compartment) without the precaution of uniformly heating throughout and without cracking or appreciable distortion of the smooth sealing line. Moreover, with such glass, dishes can be accurately formed to predetermined dimensions with no distortion of the sealing line during manufacture, so that disposable lids formed with standard dies can be used interchangeably in any dish made from the same m-old. Other materials such as the more refractory plastics, stainless steel, etc., can be used provided that they meet these requirements as to accuracy of manufacture and stability during use. Ordinarily, the

total dimensional change from the time of forming until they are ready for use should not exceed 0.1% on any dimension and shouid be substantially the same on all dimensions. i

As shown in Fig. 2, the dish 47a is of circular form and of dimensions adapted to substantially till the interior of the lower or body portion ma but leaving a small clearance or air space to avoid direct thermal conduction to the shell 13a. On the bottom of the dish are low rounded protuberances, or feet, which make tangential contact with the oor of the shell i3d. These feet are not shown in Fig. 2 but areshown at 74b in Fig 4. The outer rim 46a of dish 47a is rounded and projects beyond the rest of the dish so that theV sides of the dish can never make more than tangential contact with the sides of the shells 13a and 18a. i

On the inside of the dish Li751, the upper edge is enlarged and flared slightly outward for the reception ot' a sealing disc 53a or" special cardboard'or similar mate rial; and, in the embodiment shown in Fig. 3, an integral partition 57a extends from three points on the wail to near the center and to the height of the disc 53a, thus dividing the interior into three compartments. The top of this partition and the peripheral ledge 45a make a smooth continuous line of Contact softhat when the movable cover 53a is pressed into position, it not only makes effective contact, with resilient pressure, against the periphery of the upper wall portion 46a, but also makes a full and continuous sealing Contact with the upper surface of the ledge 45a and of the partition 57a. The disc 53a is made slightly larger than the inner periph- Y the back with `a hinge member Y3M best shown at the back of Fig. 2, and atfits front with a clamping member Refering to Fig. 4, it will be :seen mha-t *this clamping member 34a is composed of three parts pivoted together `to form la toggle. A U-shaped part is secured (e. g., by spot welding) to the body 15u. A lever part 35u is pivoted to the :arms of the U and on yan -ax-i-s spaced be. youd this the clamping head 38a i-s pi-vo'ted to the lever part 35a. This part 38a is -ormed with a mouth 76a so that it can act in either direction on hook 39a. When the toggle is pulled down, the hook a is engaged at the trop of mouth 76a to pull :the lid 15a down `onto the body 10a and compress the gasket 49a. W'Ihen the container is to Vbe opened the lever a is -swung outward and upward, lifting the mouth portion 76a, which then engages the hook 30a to lift the lid lSa against the vacuum which has ery of the upper wall portion 46a, so that when pressed down against the ledge 45a it is radially compressed. This been established therein by cooling.

A projec-on `33a :on the part 32a projects diagonally downward through ian opening 77a in 35a and across the bottom periphery of a depressed recess 36a in 35a so 'as to secure the edge of a paper disclse'al 39a between it and the part 35a. t the opposite side yof recess l36u, 4its bottom is cut out so that the remaining edge '73a engages the disc 39a and prevents itsvremovtal except lby delacing Y Y or destruction. When the lever part 35a is pulled up to release the "lid, it shears the disc 39a between 'the projecr tion 33a and the `sides :of the opening 77a, thu-s giving are formed. By this means the peripheral edge of the i disc is pressed down smoothly against the ledge a and the rest of the disc is domed Vand pressed by its own resiliency against partition 57a. lf the partition 57a is domed down toward the center, the resilient pressure of the buckled disc 53a holds the initial seal; whereas ifrthe edges of 57a are domed upward, the initial seal is held by the frictional engagement at the edge 46a and a tensile stress on the disc. that there is advantage in having the scaling edges 57a domed downward from the periphery if compartments are to be sealed from one another at the outset, It is also permissible to use a reverse curve, i. e., domed downward for a part or parts of the radius and` upward in another part or parts.

Since the covers 53a are normally put into position and pressed home while the dish and its contents are hot, and then exposed to a cooler atmosphere, a slight vacuum is quickly created within the container oy which the lid 53a is pulled down and held in pressed sealing relation even if the initial seal was not effective to seal the compartments one from another. This vacuum increases as cooling continues slowly during storage transport of the packed meal.

The lip or upper rim 46a extends sutlciently above the cover disc 53a so as to surround a space on which tableware, bread, pastries, etc., may be placed and to hold them against sliding oft it the dish is tipped with the container open.

Thus it will be seen clear indication that the container has'been opened.V So long 'as :the disc remains in place and intact, it shows that lthe contents are fresh and have not been tampered with.

The hinge member 31a, als best shown in Fig. 2, is provided with a slot adapted to receive thehook a. This slot is positioned so that when the'lid 15a is swungV down toward body portion 10a with the hook 36a in therv slot, the gaskets 40a .of the two portions will be broughtV f together ridge to ridge Vland compressed against `one another. n

The top of the. hinge member 31a is formed with rounded ears 79a at each side which serve as guides for the hook Stia. When the parts are 4to be assembled, they i are first brought together in perpendicular relation and the shank of the hook 39a dropped onto the top of the hinge member 31a between the ears 79a. The slot is ljust tar enough below the top so that in this position the hook 30a lslides readily into the slot. The ears 79a are just high enough to engage the edge of the Ishell y16a so that when the 'lid is swung downtoward the body portion these ears pry the hook .into 'the slot, but they .are short enough lso that, :once the hook is :the slot, the` lid can readily slide :over them. This Selb-aligning binge device and the .use of identical'hooks 36a at opposite sides of` the container adapted to serve either in the hinge or the clamp, greatly facilitates the assembly 'and closing lof oontainers and thus saves materially in the cost of packing meals. Y 'Y s Y lIn the use of this container as described above, a dish 47a is advantageously :rst pre-heated to lor slightly labove, l

la .temperature :at which -food to be placed therein would continue to oook. Ordinarily, about l60-170 F. will be found most satisfactory, .but this may be varied depending i Ion conditions. The foods are then separately cooked,`

either Ito completion for just short of completion and the Iseveral compartments 58a, 59a, .and 60a :are filled substantially Vwith individual servings of these Ifoods while the temperatures of both lthe dish yand the foods tare at least slightly above the temperature at which cooking will contnue. These foods are taken immediately from the cooking yoperation Without :any more delay than is necessary for the transfer; or if convenient, one or more of the foods may be 'actually cooked in the dish, especially where casserole foods lare to be served.

As soon as the several foods are lled into their respective compartments, .and 'after making sure that the upper surfaces of the peripheral ledge 45a :and of the partition 57a are clean, a lid 53a is pressed into position, using a ram which assures uniform pressure all around the peripheral edge las the lid, which is slightly larger than the opening, is radially compressed While it is pushed down over the inclined lip 46a and onto the ledge 45a. Napkins and .tableware are then placed on top =of the lid 53a and beside them bread or rolls Wrapped in a moistureproof wrapping and, for example, va piece of pie, like- Wise wrapped in a moistureproof wrapping. The cover section a is then put into position, engaging the projecv tion 30a under the self-centering hinge member 31a and then `engaging the projection 33a under the toggle clamping member 34a, and the latter is then snapped down so as to clamp the members together yand compress the gaskets into an airtight seal. Finally, ya paper disc or seal 39a is inserted int-o the recess 36a under projection 33a and pushed down until its opposite edge snaps under the edge 78a.

Ordinarily, I do not preheat the container 10a-15a and consequently the cooling of the dish 47a and its contents continues for a short time after ythe container is closed Iand until its inner shell 13a and 18a has been heated to a temperature approaching that of the dish 47a. This has the etfect of increasing-the suction by thermal contraction within the container, together with some degree of condensation of moisture. Simultaneously there occurs some thermal expansion of the air Within the container and external to the dish, which further assures that the seal will be maintained not only between the interior and exterior of the dish, but between the several compartments of the dish; and thus no exchange of flavors can occur.

Because the dish is packed Iat high temperature, the foods quickly surround themselves with an atmosphere primarily of water vapor, and by reason of the quick and eicient vsealing vof the several compartments, each 'of which is largely filled with food, very little oxygen is entr-apped. It has been shown 4that foods are kept in the container without substantial loss of flavors or of vitamin values such as would occur with Ea very much shonter holding time on a steam table [or even in a serving dish as used for serving foods in the home.

Fig. 4 shows an arrangement embodying substantially the same invention, but in addition shows how several dishes can be piled one on another in the container. In this case, a compartment dish 47h is used, substantially the same as dish 47a excepting that it is in this case shallower with respect to the height of the container section 1lb, 13b. This dish 47 b contains the several items of the main course of the dinner in the respective compartments 5%, 60h, etc. At one side of and on top of, the cover 53h of the main course dish, has been placed a semicircular dish 4712. This, like the dish 47h, is provided with an upper lip 4Gb like the lip 46h, and a ledge 45h which respectively engage the periphery and under-edge of the disposable cover 5317', but in this case there are no partitions within the dish. This dish may contain a suitable serving of soup or a pudding or other items of the meal.

The utensils, etc. in this case are placed at the right of the dish 47h. lf desired, a beverage cup may be used instead of or in addition to the dish 47b, or this dish may be divided by a partition; 0r several such dishes may be placed one beside the other. It will likewise be appreciated that if deeper or additional dishes areV desired, the thermal insulating container 10a-15a can be made of appropriate Vdepth to receive them.

In Fig. 5 is shown another alternative. In this case, a semicircular container 47C identical with that shown at 47b in Fig. 4, is used; but instead of the partitioned dish 47h, I have shown in Fig. 5 a series of individual dishes made more or less pie-shaped in outline so that they fit together within the container.

In Fig. 6 is shown a conveyor table which is advantageously used to assure accurate temperature control. The container bodies 10d and lids 15d at room temperature are fed alternately onto conveyor belt d and a dish 47d pre-heated to 170 F. is immediately placed in the body 10d. The foods are supplied in special cooking dishes 81d which facilitate rapid serving and of relatively small capacity so that exposure during serving is minimized. These ordinarily hold their temperature approximately without further precaution than avoidance of delays after cooking, but, if desired, electrically-heated thermostaticallycontrolled wells 82d may be provided on the table 83d for holding the dishes 81d. The cover discs 53d are applied as soon as the several foods have been served from the dishes 81d into dishes 47d, all Without stopping the belt 80d or removing the container from it. Immediately, wrapped breads, pastries, etc. and utensils, napkins, etc. are laid on the cover disc and the lid 10d then placed and clamped.

The belt 80d runs at a iixed speed predetermined to complete these operations Within a deflnitely fixed period. The atmospheric conditions are known and kept reasonably stable and the temperatures at which the dishes and foods and containers, utensils, etc., are supplied is known. Thus, by relating these factors, the heat in the container as it is closed is definitely predetermined.

As described above, the dish itself is preferably of heavy material such as oven glass or some similar material which will absorb heat and retain the heat, releasing it slowly as needed, so as to maintain the foods in their desired hot condition.

'I'he dish may be charged with infrared rays to the desired temperature. It is found that when the temperature in the core of the dish is around 250 F., or more, the skin temperature of the dish is much lower and may be F. or less, so that the foods being packed within the dishwill not resume cooking. Other means for injecting deep heat into the dish and into the core thereof and in controlled uniform amounts to insure against overcooking after the dish is sealed within the insulated containers or compartment, may be employed, the deep heat of the dish serving to insure that the packaged meal has the desired serving temperature at the point of destination. The heavy heat-absorbing dish acts as a heat booster or heat-storage battery to offset the relatively small amount of latent heat within individual portions of hot foodsafter separation from and preparation in bulk amounts.

Even when the flexible disc is omitted, it is found that by placing the dish within an insulated container which is maintained at about room temperature, the dish loses heat to the Walls of the container and thereby forms a vacuum within the container which is effective in preventing the aroma and avors of one of the foods within the dish from intermingling with the other foods.

In the preferred operation, the heat-retaining dish is charged with infrared or other means for injecting deep heat into the dish, and hot individual meals are placed within each dish. The dish is carried upon a belt or packing table and then introduced into a container preferably maintained at about room temperature, the container being sealed to provide an insulated chamber about the dish and permitting a self-forming vacuum to prevent the intermingling of flavors, aromas, etc.

While in the foregoing specification I have described the containers which are employed for sealing individual hot meals Vin a yself-forming vacuum as being made Vof metal, such as stainless steel, it will be understood that such containers may be made of any suitable materials favoring heat retention and having low heat transfer, such as, for example, molded plastics berglass, ceramics, wood, etc., and such containers may vary widely in design and construction in accordance with the number or" inner dishes contained, the length of heat hold desired, etc. While also, l have described the use of a hypoderrnir.` needle inserted through the gasket for evacuating airj between the shells,`it will be understood that any suitable means may be employed. For example, the shells may be provided with small vent holes in the inner pans at points Where `they Serve as vents during assembly, but s located that such holes become self-sealing after the Y gasket is'seated in its inally-a'ssemblel location.

lt'will be noted that the dish or dishes, after their removal fromV the container, constitute a hot dinner plate from which the individual meal may be eaten',V without re-dish'ing or re-portioning. Y

While, in the foregoing specication, I have set forth a specific process or method in considerable detail for'the purpose of illustrating the invention, it will be understood that such details may beV varied widely by those skilled in the art without departing from the spirit of my invention.

Iclaim:

V1. In a method for preserving over a substantial period an individual meal consisting of hot foods, with substantially the original freshness of the prepared foods, the steps of preheating a dish having associated therewith a thick heatfetaining body to a temperature above about 160 P., introducing the prepared 'hot foods into the dish, enclosing the heated dish and food within a container so that the vapors rising from the food till the upper portion of the container, sealing the container against the preheating thereof.

3. In a method for preserving hot foods hot over prolonged periods without substantial loss of avor and Y aroma, the Ysteps of preheating an ovenware glass dish having thick heat-retaining walls to a temperature of about 160170 F., introducing cooked hot foods into the dish in spaced-apart relation therein, immediately enclosing said dish and the food therein Within an in-t sulated container so that the vapors rising from the food substantially ill thevupper portion of the container and displace the air in the upper portion of Ythe container,-` sealing said container against the ingress of air, andmaintaining said container at about room temperature to con.

dense vapors therein to form a partial vacuum about the upper exposed areas of said food,r while the lower non-exposed areas of said vfood remain in contact with said heated dish.

4, in a method for serving an individual meal'cohsisn. ing of hot foods after a prolonged period of storage soY that the hot foods retain substantially the original fresh.

condensing the vapors in said -container to provide aV partial vacuum about the upper exposed areas of the food,V thus preventing the intermingling of the Yaromas andV flavors of the individual food portions within the dish.

5. In a method for preserving an individual hot meal while contained within a single dish without substantial Y loss of avor or aroma, the steps of preheating an individual meal dish made of thick ovenware glass to charge the same with penetrating heat and to a surface temperature of at least 160 F., introducing cooked food portions for an individual meal into said dish, immediately andv i while vapors are arising from said food portions, enclosing the heated dish and the food therein Within a chamber to permit the vapors from the food to substantially'll said chamber, sealing the chamber against the ingress of air and about said'food, cooling said chamber to bring about a condensation of the vapors therein and to form a vacuum about the outer exposed surfaces of said/food` while the inner surfaces of said Vfood are in contact with said preheateddish, and opening said chamber to expose said dish with the individual meal thereon. Y

2,436,097 Clarke Feb. 17, 1948 Reed Jan. 13, 1953V 

1. IN A METHOD OF PRESERVING OVER A SUBSTANTIAL PERIOD AN INDIVIDUAL MEAL CONSISTING OF HOT FOODS, WITH SUBSTANTIALLY THE ORIGINAL FRESHNESS OF THE PREPARED FOODS, THE STEPS OF PREHEATING A DISH HAVING ASSOCIATED THEREWITH A THICK HEAT-RETAINING BODY TO A TEMPERATURE ABOVE ABOUT 160*F., INTRODUCING THE PREPARED HOT FOODS INTO THE DISH, ENCLOSING THE HEATED DISH AND FOOD WITHIN A CONTAINER SO THAT THE VAPORS RISING FROM THE FOOD FILL THE UPPER PORTION OF THE CONTAINER, SEALING THE CONTAINER AGAINST THE INGRESS OF AIR, AND MAINTAINING THE CONTAINER AT ABOUT ROOM TEMPERATURE TO CONDENSE THE EVOLVED VAPORS WITHIN THE CONTAINER TO FORM A PARTIAL VACUUM ABOUT THE UPPER EXPOSED AREAS OF SAID FOOD WHILE THE LOWER NON-EXPOSED AREAS OF SAID FOOD REMAIN IN CONTACT WITH SAID HEATED DISH. 